The Beauty of a Phase-overlapping Last Planner System with incorporated Takt

Annett Schöttle, Refine Projects AGClaus Nesensohn, Refine Projects AG

BACKGROUND BASED ON LITERATURE

Toyota ProductionSystem (TPS)

Toyota ProductionSystem (TPS)

Last Planner System (LPS)

Last Planner System (LPS) TaktTakt

minds + hands philosophyof the craftsmen/-women

+work standardization and

assembly line

production planning and control system

LP integration to develop a reliable network

work structuring method

standardization and clear batch size

Commitment, Teamwork, Empowerment & Training

Incorporation

RESEARCH QUESTIONS AND METHOD

1. How does LPS function as a production system across the whole project and which role does takt play in the LPS?

2. How to design a production system for all project phases?

Action research during the project

Case study research after the support

• 21 interviews• Lean close-out

workshop for reflection

• Discussions• Meeting and plus

delta evaluation• Observations

+

(PORR Design & Engineering GmbH)

PROJECT OVERVIEW

Lean Close-outFebruary

Supported by Author 1

Request for BuildingDecember

StartFoundationJune

Start LPSdesign phaseOctober

Start LPSon siteJune

Supported by Author 2

Start InstallationInteriorJanuary

End LPS design phaseDecember

ConstructionalCompletionDecember

End LPSon siteDecember

StartFurnishingJanuary

StartInspectionOctober

2018

Project StartSeptember

2016 20192017

Overall Process Analysis (common understanding)

Milestone & Phase Plan(weekly basis)

Weekly Workplan(daily basis)

6 Week Lookahead(daily basis)

Learning(improve)

Takt for repeatable areas

Specific arears with no sequence repetition

Only applied during construction and inspection

• Ground floor• Basement• Roof• Outside facilities• Commissioning

• Shell • Interior office space 1. – 3. floor • Interior core area 1. – 3. floor • Exterior (partly)• Inspection 1. – 3. floor

VIENNADesign Phase Pull

MUNICHConstruction Phase

REASONS TO ADJUST THE TAKT

No error-free and no on-time delivery of construction documents Limited availability of resources in the market Lack of timely involvement of trades Shortage of subcontractor availability Shortage of labour Variable performance by the different work crews of a trade No availability or late delivery of material Late change orders by the client Delayed decision-making by the client

How often do you think this happens?

CONSIDER THE HUMAN FACTOROne team consisting of…1. Different personalities

2. Different attitudes and behaviours

3. Different languages

4. Different experience

5. Different learning speeds

6. Different expectations

PRODUCTION SYSTEMMajor outcomes LPS triggers minds + hands thinking

LPS is a driver for productive conversation

Takt is a good tool for repeatable areas

Keep takt flexible for improvements

Overall Process Analysis (common understanding)

Milestone & Phase Plan(weekly basis)

Weekly Workplan(daily basis)

6 Week Lookahead(daily basis)

Learning(improve)

Takt for repeatable areas

Specific arears with no sequence repetition

Only applied during construction and inspection

CONCLUSIONDesign a production system that… Easily engages people to collaborate

Span from design till handover

Serves as marketplace for information, planning, re-planning and communication

Integrate knowledge of the Last Planners

That gives the team flexibility

And where Team members feel free to voice their concerns

Adjust based on the teams needs and product request

Supported by the different organizations